Building unit and method of manufacture thereof



May 2, 1939. 1 KlRScHBRAUN 2,156,566

BUILDING UNIT AND METHOD OF MANUFACTURE THEREOF Filed April 16, 1935 2 Shee'ts-Sheet 1 "/9 I} INVENTOR ?5 155 we Mes CWBEAL/N.

2 5, W l I? ATTORNEY May 2, 1939. L. KIRSCHBRAUN BUILDING UNIT AND METHOD OF MANUFACTURE THEREOF Filed April 16, 1935 2 Sheets-Sheet 2 INVENTOR {Es reze jean/53A U/Y- ATTORNEY Patented Ma 1939" ammo UNIT AND METHOD or mmm c'ruan rnsanos Kirschbraun, New York, N.-Y., assignor to Thei Patent and licensing Corporation, New York,N. Y., a corporation of Massachusetts 7 Application April 16, 1935, Serial No.'16,557

3 Claims. (01.20-)

I by preforming themain body portion of the-unit.

- from a plastic composition of water-resistant Another object of the invention is to provide a unit of this type in which the body portion of plastic composition is reinforced on the lower face thereof with a thin sheet of flexible felted material, and on the opposite face'thereof, which is to be exposed to'theweather, with a sheetof flexible material carrying a" surfacing layer. of mineral grit as that commonly employed in making rooting, for the purpose of imparting to the finished unit desired ornamental eifects. 1"

In its preferred form, the unit of invention :is designed to simulate the appearance of brick or other'm'asonry construction when a plurality of the unitsare laidin proper relation on a .vertical side wall; and; to this end, the preferred form of the unit is formed along its upper and lower longitudinalmargins with flanges so ared and'dlmensioned'that'when properly assembled, the 'flange on the'lower longitudinal boundary of onefunit will cooperate with the so flange on the upper longitudinal boundary of the subjacent unit to provide an emcient lap between the adjacent units and at the same time leave a longitudinally extending depression between certain portions of the adjacent units to simulate.

:5 horizontal mortar lines of brick or other masonry construction.

, with the foregoing and other objects in view,

I have designed the unit, and a method for making the same, to be more fully hereinafter de-' 40 scribed, depicting the same, as well as can be.

in the accompanying drawings. in which: Figure 1. shows, in perspective, a unit constructed in accordance with the invention;

Fig. 2 is a transverse cross-section through the 45 unit along liner-2 of Fig. l; Fig. 3 is a plan view of an assembly of such units as theywould appear when laid; v

Fig. 41s a vertical section taken along the line 4-4 of Fig. 3-; 60 Fig. 5 is a view, partly in perspective andpartly in cross section, showing one method by which the units of my invention may be produced; and

Fig. 6 is an elevational view of the forming rolls shown in Fig. 5 for use in carrying out the method 55 of producing the units.

Referring-first tojFigs. l, 2 and 4, the unit as therein shown comprises essentially a main core or body portion l0, elongated in its longitudinal dimension, a reinforcing sheet Ii on the lower face thereof, and a reinforcing sheet I! on the 5 upper face thereof. v

- The core Ill is constituted of a hardened-piss tic mixture consisting essentially of asphalt, fiber and mineral or other hardening fillers such as ground slate, talc. mica or the like, or combina- 1o tions thereof. Theproportions of the several ingredients constituting-the core may vary. within considerable limits'so long as the composition has the character of being plastic at elevated. temperatures but substantially rigid at normal is atmospheric temperatures. From the standpoint oi. convenience andeconomy, this core may consist of disintegrated and homogenized scrap or. waste asphalt roofing, substantial quantities of which are ordinarily accumulated in the manu- 20 I I iacture of asphalt prepared roofing. This scrap of waste material is generally composed of about 50150 60% asphalt, 15 to 20 fiber and 25 to 35% mineral matter. If necessary or desirable, the

scrap may be compounded with further quanti- 2o ties 'of' asphalt, fiber and mineral or organic finer sufilcient to impart the desired rigidity" and strength. Within the limits above stated, the. composition of the core may readily be made such that at temperatures of from 200 to 300 F., it can be extruded or otherwise formed under pressure to desired. shape. In order still further to indicatethe character ofthe core composition, it may be stated that. as distinguished from ordinary asphalt or mineral filled asphalt 001m positions such as are normally employed for. coating prepared roofing. the core composition to be employed in accordance with my invention, while deformable under pressure and at elevated I temperatures, is not liquefiable by heat as are 40 the ordinary asphalt or mineral filled asphalt coatings. In fact, the mastic asphalt composition here contemplated and containing fiber and mineral filler admixed .in the proportions above indicated with the asphalt, are practically infusible at elevated temperatures; and as already stated, it assumes a substantially rigid condition at normal atmospheric temperatureawhere as ordinary asphaltic coatings even when containingsubstantial amounts of mineral filler are so in no sense self-sustaining.

-. The core 10 of the unit is formed along the upper longitudinal boundary thereof with a flange I5 by depressing or removing the mastic. material along the longitudinal zone extending 5g site face of the core, this flange I9 being prefer-.

ably of a transverse width approximately onehalf that of the flange I 5 and extending upwardly from the lowermost edge 20 of the core to the point indicated by the shoulder 2|. Desirably,

Y the flanges I5 and 9 are each of a thickness'onehalf that of the main part of the core. They may, however, be of different thicknesses, but in any case, the sum of the thickness of the two flanges should equal substantially the thickness of the main part of the core.

As shown, the reinforcing sheet I I on the lower face of the core body extends from the upper longitudinal edge I6 thereof to the shoulder 2| adjacent the lower edge. The reinforcing sheet I2, secured to the upper face of the body extends from the shoulder I to the lower longitudinal edge 20 of the unit.

The sheet II, which ser es to reinforce the core, preferably consists of a thin sheet of waterresistant material such as asphalt saturated felt of a light'grade variety. Materials other than asphalt saturated felt may, however, be used in place of the sheet II, such for example, as ordinary kraft paper, saturated with asphalt or other waterproof material.

The sheet I2, afiixed to the upper face of the element, consists preferably, of a. thin grade of asphalt saturated felt, having a layer of asphalt coating on its upper or outermost face, in which said coating is embedded a layer of crushed mineral grit or otherwear-resisting and decorative surfacing material 22. The sheet I2 as thus constructed serves not only to increase the structural strength of the finished unit, but also to provide the latter with the desired decorative finish by virtue of the mineral grit 22 which latter can readily be, and is preferably, applied to the sheet I2 in much the same manner as ordinary asphalt coated and mineral surfaced roofing is made, prior to laminating the sheet to the core body It).

In order that the finished unit shall simulate brick or other masonry construction when laid,

the layer of mineral surfacing 22 may be scored transversely or otherwise formed at suitably spaced intervals with transversely extending indicia as indicated at 23 to simulate vertical joints of brickwork. In lieu of scoring the mineral surfacing layer along these narrow transverse zones, the mineral surfacing may be gouged or otherwise removed therealong; or the mineral surfacing may be omitted to expose the black color of the asphalt coating on the sheet -l2; or the mineral surfacing at these areas may be covered with suitable paint or the like. In any case, however, it will be preferable that the transverse indicia 23 to simulate vertical mortar joints be provided on the sheet I2 during the fabrication of the sheet, although in some instances it may be desirable to form these indicia in the finished. unit after the sheets II and I2 have been laminated with the core body III.

In Figs. 3 and 4, there is shown the arrangement of the units when applied to a vertical side wall. From these figures, it will be seen that the units are laid in successive partially overlapping ,courses. The adjacent units'of each course may be either butted, or slightly spaced from one an- Referring particularly to Fig. 4, it will be noted that the units are laid with the wider flanges I5 uppermost and with the opposed lower flange I9 of the units of each course overlapping, to their fullest possible extent, the uppermost flanges I5 of the units of the preceding course, so that the shoulder 2| thereof will be in facial contact with the edge I6 of the units in the preceding course. Likewise, the inner surface of the flange I9 will be in facial contact with the outer face of the flange I5 on the units in the preceding course, along the upper margin thereof. In this way, there is left between the lower edge 20 of each unit in each course and the shoulder II of the units in the preceding course, a narrow longitudinal depression of a depth such that the same simulates the horizontal mortar joints of brick or other masonry construction. Also, it will be noted that the arrangement, at the points where the units of each course overlap the units of the preceding course, is such that any water flowing over the surface and entering the horizontal depressions 25 will flow off across the surface of the subjacent .units before reaching the supporting structure 26. Thus, in order for water to reach 'the supporting structure it would be necessary for the water to creep upwadly between the contacting faces of the flanges I5 and I9 and the contacting edges I6 and 2|.

The units may be secured to the supporting structure 26 in any suitable and convenient manner, as for example, by nails driven through the flanges I 5 before the next succeeding course of units is laid and, if desired, also by means of copper or other rust-resisting nails driven through the exposed portion of the units at suitable intervals therealong.

In Figs. 5.and 6, I have shown means whereby the units as above described, may be produced. In these figures, the numeral 30 represents a nozzle or die which may be attached to any known form of auger or pressure feeding machine for forcing the plastic composition of the core through the die or nozzle 30 by means of which the plastic material of the core is extruded in the form of a continuous sheet or layer issuing from the mouth of the die.

In the arrangement shown in Figs. 5 and 6, the nozzle or die is of a length which will extrude a sheet of the mastic sufliciently wide to make possible the continuous and simultaneous production, longitudinally of the sheet, of five rows of units across the width of the sheet. It will be understood, or course, that this number may be either increased or decreased as conditions may require.

On one side of the nozzle is shown a mandrel indicated at 3| which may be supported in any convenient manner (not shown) and upon which are mounted five slightly spaced rolls or ribbons of sheet material to constitute the reinforcement I I for the lower face of the body of the units to be formed. The material of each of these rolls will be of a width corresponding to the dimension 'from the edge I6 to the shoulder 2| of the unit the inside of the successive convolutions.

Below the mouth of the nozzle and slightly forwardly thereof, are arranged a pair of vertically 75 any convenient point beyond the apparatus shown arsaeee spaced forming rolls 85, 38, these forming rolls being mounted for rotation upon parallel shafts 81 arid 38 respectively, the shafts being suitably iournaiied in bearings (not shown). The upper 5' forming roll 35 is formed on its surface with a series of collars 39, 890:. In the particular arrangement here shown, the collar 89a, is formedat one end of the roll 35 and the four additional collars 39 are formed .at spaced intervals axially l sion from the shoulder H to the edge 2d of the units to be produced. Each of the collars 88, 38a is of a width axially of the roll corresponding to I the dimension of the flange l5.

I The lower forming roll 38 is similarly formed gg aim of the flange i9. The collars 39,3 are of a radial thickness corresponding to the overall 1 thickness of the unit minus the distance from theouter surface of the sheet i i, to the surface of the flange i5, whereas the collars it, Mia are of an a radial thickness corresponding to the overall thickness of the unit minus the distance from .the outer surface of the sheet l2" to the surface of the flange I9.

The shafts 37, 38 will be spaced from each other 5 vertically at such a distance that the nip between the surface of therolls 35, 36, intermediate the collars will be of athickness corresponding to the overall thickness of the unit to be produced.

By thus arranging the forming rolls 35, 38 and 40 their respective collars, one circumferential edge of each of the collars 39 will rotate substantially in contactwith the opposed circumferential edge of the adjacent corresponding collar til on the roll 36. This will serve to weaken, if not actu- 5 ally sever, the mastic longitudinally at these points simultaneously with the formation of the flanges i5, it by the collars and with the aflixing of the ribbons constituting the sheets H and H to the mastic 'core body.. If desired, these con- 50 fronting circumferential edges of the'collars 8d and 40 may be extended or otherwise formed so as to constitute slitting knives for this purpose.

If not soformed, and the units of each row are not severed at this point from the units of the adjacent row, slitting mives may be mounted at in Figs. 5 and 6 for slitting the units of one row from those of an adjacent row.

From the foregoing description, it will be ap-' parent that the ribbons which are to form the sheet ii of the finished unit may be threaded from the mandrel 8| into the nip between the forming rolls 35, 36 and guided over the portions of the roll 36 intermediate the collars 40 and 40a. Likewise the ribbons of mineral surfaced material to be aiiixed to the upper surface of the core may be fed from the mandrel 32 and around the surface of the forming roll 35 and into the portions of the nip intermediate the collars 39, 39a In thus traversing the periphery of the roll 35, each of the ribbons from the rolls on the mandrel 32 will, in passing between and beyond the nip of the forming rolls, become reversed from the position occupied in the rolls so that the mineral surfaced face of these ribbons is outermost with reof the roll corresponding to the transverse dimen- -s V e lation to the mastic core body. while the opposite min-face? of these ribbons becomes aflixed to the upper surface of the mastic core.

As the sheet of mastic issues from the mouth of'the die 39, it will thus bereceived between the opposed faces of the ribbons fed from the mandrels 3| and 3 2 and be carried therewith through the nip between the forming rolls. In passing through the'nip, the mastic. as will be .more clearly apparent from Fig. 6, will be displaced or deformed on one face'thereof by the collars 39,

89a to provide the flange 5 for the units of each row being formed. At the same time. the mastic will be displaced or deformed from the opposite race thereof by the collars 60, 50a and thereby,

bring to shape the flanges is on the units of each row. The adhesive properties of the mastic ma- ,terial of the core, at the elevated temperatures employed as will be understood by those skilled in the art, is sumcient to cause the ribbons or webs ou the opposite surfaces thereof to become securely afixed thereto, particularly under the pressure of the rolls 85, 33. If necessary, addi-.- tional'press rolls (not shown) may be located at any convenient point beyond the forming rolls to insure the firm adhesion of the upper and lower ribbons to the core body.

After the ribbons have thus been united and consolidated with the core body, the consolidated sheetmay be cooled in any convenient fashion and the finished units of each row severed transversely to any desired length by meansof any to desired length may be effected by a single transverse chopper or cutting knife cutting through the units of all of the rows medially of selected ones of the indicia. v23, depending upon the length of unit desired and the spacing ofthe indicia. a

. In some instances it may be desirable that the units be of tapering cross-sectional thickness transversely thereof.- The method and apparatus above described lends itself readily to the production of units as herein described, but of transverse tapering thickness. For this purpose, the

surfaces ofeither or both of the forming rolls,

intermediate the collars thereof, as well as the surfaces of either or both sets of collars, may be made of varying diameter. In this way the nip between the forming rolls and the collars thereon may be made to assume the desired taper axially thereoffor each row of units to be formed therebetween.

Units such as herein described may be fabricated of greater relative width. and provided with flanges corresponding to the flanges l5 and i9 (but which flanges are of equal transverse dimension) and a facing sheet with or without mineral surfacing as desired. Such units would serve well as slabs for flat roof decks, flooring or the like.

Having thus described the invention, and 'several modes in'which the same may be carried out, it will be apparent tothose sidlled in the art that various changes may be made therein without departing from the scope thereof as defined in the claims hereto appended.

What I claim as my invention is:

1. A weather facing building unit comprising a core of hardened plastic material including asphalt, fiber and hardening fillers, said core having an upwardly facing flange on one face thereof along one of its longitudinal edges and a downwardly facing flange on the opposite face thereof along its opposite longitudinal edge, the first named flange being of greater transverse dimension than said second named flange, a layer of asphalt saturated felt aflixed to the first named face and adapted for exposure to the weather, one Y longitudinal edge of said layer terminating along the inner edge of said first named flange and the other longitudinal edge of said layer terminating along the outer edge of said second named flange, and a sheet of flexible material afflxed to said opposite face.

2. A building unit comprising a core of harddened plastic material including asphalt, flber and hardening fillers, said core having an up- 25 wardly facing flange on one face thereof along one of its longitudinal edges and a downwardhr facing flange on the opposite face thereof along its opa ia es posite longitudinal edge, the first named flange being of greater transverse dimension than said second named flange, a layer of asphalt saturated mineral surfaced felt aflixed to the first named face, one longitudinal edge of said layer terminating along the inner edge of said first named flange and the other longitudinal edge of said layer terminating along. the outer edge of said second named flange, and a smooth surfaced flexible felted material affixed to said opposite face.

3. A surface covering for walls or the like comprising courses of units each of said units comprising acore of hardened plastic material including asphalaiiher and hardening fillers, each of said cores having an upwardly facing flange along the upper edge of the outer face thereof, a

narrower downwardly facing flange along the,

loweredge of the inner face thereof, a sheet of asphalt saturated mineral surfaced felt secured to said outer face and extending from edge to edge thereof, and a sheet of smooth surfaced felted material secured to said inner face, said narrower flanges of the units in each course partially overlapping the said wider flanges of units in the preceding course.

LESTER KIRSCHIBRAUN. 

